Improving Equipment Availability and Reliability Using the ... - OSIsoft
Improving Equipment Availability and Reliability Using the ... - OSIsoft
Improving Equipment Availability and Reliability Using the ... - OSIsoft
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23 September 2011<br />
WESTIN GARDEN CITY,<br />
MUMBAI<br />
<strong>Improving</strong> <strong>Equipment</strong> <strong>Availability</strong> <strong>and</strong> <strong>Reliability</strong><br />
<strong>Using</strong> <strong>the</strong> PI System<br />
Presented by: Mr. KP Srivastava - Senior Manager<br />
UltraTech Cement Limited<br />
Unit: Narmada Cement – Jafarabad works<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 1
Agenda<br />
* PI system in UTCL-NCJW plant network<br />
* Specific Utilization of various PI utilities<br />
* Latest Development<br />
* Problems <strong>and</strong> Limitations<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
2
Server-1<br />
E<strong>the</strong>rnet<br />
Switch 1<br />
Configuration of PI Network at NCJW<br />
Server-2<br />
E<strong>the</strong>rnet<br />
Switch 2<br />
E<strong>the</strong>rnet to<br />
OFC<br />
converter<br />
OFC to<br />
E<strong>the</strong>rnet<br />
converter<br />
E<strong>the</strong>r<br />
net swt.<br />
PLG server<br />
PLC 1 PLC 2 PLC 3 PLC 4 PLC 5 PLC 6 PLC 7<br />
Fire<br />
wall<br />
QCX server<br />
LAN- PCs<br />
( USERS )<br />
PI server
Business challenge/problem addressed<br />
Process <strong>and</strong> QC data not available to maintenance <strong>and</strong><br />
operation team at <strong>the</strong>ir workplace.<br />
Process <strong>and</strong> QC data have been available in SCADA or Quality<br />
control system server.<br />
Operation <strong>and</strong> maintenance persons has to call to CCR operator<br />
for process data <strong>and</strong> chemist for quality related data. It<br />
creates lot of nuisance which leads to mistakes <strong>and</strong><br />
communications failures.<br />
Solution<br />
Process <strong>and</strong> QC data made available to maintenance <strong>and</strong><br />
operation team at <strong>the</strong>ir workplace through PI System<br />
ProcessBook application.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
4
Screen developed by maintenance crue<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 5
Process view of kiln<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 6
Process view of Coal Mill<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 7
Benefits<br />
1. Plant operation <strong>and</strong> Quality related data can be view<br />
by maintenance crew <strong>and</strong> operating crew at <strong>the</strong>ir work<br />
place on <strong>the</strong>ir own PC through LAN connection.<br />
Process flow diagram can be developed for each<br />
section separately <strong>and</strong> process <strong>and</strong> quality parameter<br />
can be shown in flow diagram for better<br />
underst<strong>and</strong>ing.<br />
2. Customized screens can be developed by<br />
maintenance team to monitor <strong>the</strong>ir ownership<br />
equipment related data for better maintenance<br />
practices <strong>and</strong> proactive approach.<br />
3. Nuisance to operator <strong>and</strong> chemist are reduced by<br />
minimizing unnecessary communication <strong>and</strong> chances<br />
of error in verbal communication.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 8
Business challenge/problem addressed<br />
2. There is no way to find process <strong>and</strong> quality parameter<br />
after certain time.<br />
Many parameters are required to refer over a period of time for<br />
improvement / analysis purpose. SCADA has limitations <strong>and</strong> it can<br />
save historical data for a small period of time.<br />
Solution<br />
PI Server archived <strong>the</strong> Data in compressed form <strong>and</strong> stored <strong>the</strong> data in<br />
large amount for a longer period. We can get each parameter<br />
value for every second for last 3 years. It can be view in <strong>the</strong> form<br />
of trend or it can be retrieved in <strong>the</strong> excel sheet.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 9
Business challenge/problem addressed<br />
3. There is no way to monitor real time data of o<strong>the</strong>r<br />
similar unit.<br />
We do not have <strong>the</strong> system to monitor <strong>the</strong> o<strong>the</strong>r unit parameters for<br />
comparison for improvement projects.<br />
Solution<br />
We can monitor real time <strong>and</strong> au<strong>the</strong>ntic data of all <strong>the</strong> manufacturing<br />
units of Ultratech Cement from any one of <strong>the</strong> manufacturing unit<br />
as well as from head office. DataLink is being used to compare<br />
data in <strong>the</strong> excel sheet. Similar units data are taken on excel sheet<br />
for comparison for bench marking <strong>and</strong> improvement projects.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 10
Case study # 1<br />
Application : Cement Bag Counter <strong>and</strong> Dispatch Reconciliation<br />
Before ( Problem ) After ( Solution)<br />
1 Earlier <strong>the</strong>re was no System to reset <strong>the</strong> counter from<br />
site by Dispatch Supervisor(Person of PP operation)<br />
2 Since <strong>the</strong> end of dispatch on daily basis was not<br />
identified at PI, <strong>the</strong> counts were never used to<br />
compare with actual dispatch <strong>and</strong> so <strong>the</strong> use of PI for<br />
bag counts was not effective.<br />
3 The time at which dispatch fininsed changes day to<br />
day basis ,due to nature of operation <strong>and</strong> manual truck<br />
loading .So counter reading based on time ( ideally at<br />
12.0 night )was never in match with dispatch.( Sample<br />
PI Graph enclosed)<br />
4 Two bags going simultaneously <strong>and</strong> counted as one<br />
due to less gap between <strong>the</strong>m. This happens<br />
sometimes due to misoperation /malfuction at packer<br />
Provided <strong>the</strong> Reset switch for counter ,taken into PI<br />
System <strong>and</strong> instructed <strong>the</strong> Supervisor to reset <strong>the</strong><br />
counter at <strong>the</strong> end of each date when dispatch of<br />
<strong>the</strong> date is closed.<br />
Since <strong>the</strong> time at which <strong>the</strong> dispatch is closed is<br />
identified at PI , The counts in it can be used for<br />
comparison with actual dispatch.<br />
Even after change of time from sharp 12.0 night ,<br />
due to operational constraints, <strong>the</strong> end of dispatch<br />
of <strong>the</strong> date can be identified in PI system <strong>and</strong> so <strong>the</strong><br />
bag counts can be compared with actual dispatch.<br />
The problem is overcome by sensitive photosensor<br />
as it can detect even minor gap.( This problem shall<br />
not add in effectiveness of Bag counter system as<br />
in this condition , <strong>the</strong> bag counts will be less than<br />
<strong>the</strong> dispatch by number of times such phenomenon<br />
happened. Since <strong>the</strong> counts are less than actual<br />
dispatch, <strong>the</strong> challenge is over, ). The challenge is<br />
bag count more than <strong>the</strong> actual dispatch*20<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
11
Cement Bag Counter recorded in PI with reset<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
12
Case study # 2<br />
<strong>Equipment</strong> name:<br />
Crusher H.T. Motor( B7 )<br />
• Problem Faced<br />
• Whenever H.T. motor gets tripped on Thermal<br />
Overload , Sometimes it was found that <strong>the</strong> current<br />
value in <strong>the</strong> SCADA point trend was normal.<br />
• So it was very difficult to convince <strong>the</strong> MINES as well<br />
as PROCESS dept., that it was an actual tripping due<br />
to rise in current value above specified value.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
13
© Copyright 2011 <strong>OSIsoft</strong>, LLC 14
• LIMITATION<br />
• Point trend of any analog value gets updated in <strong>the</strong><br />
present SCADA system after every 10 sec.<br />
• But <strong>the</strong> delay for Thermal Overload tripping of <strong>the</strong><br />
crusher Motor is 3sec.<br />
• So <strong>the</strong> actual current value at <strong>the</strong> time of tripping, is<br />
some times not recorded.<br />
• Advantage of PI System<br />
• Updating time of PI System is 01 sec<br />
• Resolution of PI System is higher than SCADA system.<br />
• The ACTUAL Current Value at <strong>the</strong> time of tripping is<br />
recorded in PI.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 15
Ad-Hoc Trend<br />
60<br />
50<br />
40<br />
30<br />
20<br />
10<br />
0<br />
7/27/2008 8:00:00 PM 3.00 hours<br />
7/27/2008 11:00:00 PM<br />
NCJW CRU & REC CURRENT LS CRSHR MOT B7<br />
17.859<br />
A<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 16
Manual Data entry for QC parameters<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 17
Connecting PI System with Colony TV Network<br />
Internal LAN Network<br />
PI Server<br />
Plant E<strong>the</strong>rnet Network<br />
PLC<br />
Way forward….<br />
CCR SERVER ROOM TV ROOM<br />
WIRELESS LAN Network<br />
Internal LAN Network<br />
6 Kilometer<br />
PI<br />
Terminal<br />
AGP<br />
CARD<br />
MODULATOR<br />
CABLE<br />
NET WORK<br />
COLONY<br />
TV<br />
TV<br />
TV<br />
18
© Copyright 2011 <strong>OSIsoft</strong>, LLC
23 September 2011<br />
WESTIN GARDEN CITY,<br />
MUMBAI<br />
<strong>Improving</strong> <strong>Equipment</strong> <strong>Availability</strong> <strong>and</strong> <strong>Reliability</strong><br />
<strong>Using</strong> <strong>the</strong> PI System<br />
Presented by: Manu Singh – Senior Engineer (Instrumentation)<br />
UltraTech Cement Limited<br />
Unit: Aditya Cement Works - Shambhupura<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 20
FLS OPC Server<br />
Crusher OPC Server<br />
CBA OPC Server<br />
LINE-2 OPC Server<br />
EMS OPC<br />
Server<br />
PI System Architecture at Ultratech Cement Ltd<br />
(Aditya Cement Works Shambhupura )<br />
PLC Network<br />
PI-Server<br />
TPP OPC Server<br />
First Unit to use PI System in Cement<br />
Office LAN-<br />
PCs<br />
Web Clients<br />
Office LAN<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC
PI ProcessBook Application<br />
PFCC Cooler Status monitoring<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC
Performance Calculations<br />
Logging of Quality parameters<br />
Generating process log sheets<br />
Logging of Quality lab parameters<br />
Run Hours <strong>and</strong> Batch Counters report<br />
Bag Counter <strong>and</strong> Dispatch report<br />
<strong>Equipment</strong> condition monitoring<br />
Daily power <strong>and</strong> output analysis<br />
Shift Operator Performance report<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC
Logging of Quality Lab Parameters<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC
Packing Plant Bag Counter Report<br />
10 Nos of PI tags + PI DataLink features makes <strong>the</strong> report available on a single<br />
click, By entering date in a cell, history data can be called.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC
Manual Discharged Bag Counter Report<br />
• Helps while maintaining <strong>and</strong> achieving six- sigma level<br />
• History data can be called by altering date Excel formula<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC
Example 1 : Condition Monitoring<br />
On line monitoring of critical parameters ( Current data )<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
2
Kiln - Unit 1<br />
Sl.<br />
No<br />
PI Tag No Descriptor<br />
Kiln support Rollers<br />
1<br />
2<br />
3<br />
4<br />
ACS KN TEMP KILN<br />
ROLLER1 1<br />
ACS KN TEMP KILN<br />
ROLLER1 2<br />
ACS KN TEMP KILN<br />
ROLLER1 3<br />
ACS KN TEMP KILN<br />
ROLLER1 4<br />
Kiln main drive & Girth gear<br />
5<br />
6<br />
ACS KN TEMP KN301 MTR<br />
DE BRG<br />
ACS KN TEMP KN301 MTR<br />
NDE BRG<br />
7 ACS KN TEMP KN301 GB 1<br />
8 ACS KN TEMP KN301 GB 2<br />
9 ACS KN TEMP KN301 GB 3<br />
10 ACS KN TEMP KN301 GB 4<br />
Example 2 Condition Monitoring<br />
On line monitoring of critical parameters ( Historic data )<br />
KILN ROLLER BEARING<br />
STATION 1 TEMP-1<br />
KILN ROLLER BEARING<br />
STATION 1 TEMP-2<br />
KILN ROLLER BEARING<br />
STATION 1 TEMP-3<br />
KILN ROLLER BEARING<br />
STATION 1 TEMP-4<br />
Eng<br />
Unit<br />
Alarm 1 Alarm 2 Trip<br />
0C 55 68<br />
0C 55 68<br />
0C 55 68<br />
0C 55 68<br />
KILN MTR 301 DE BRG 0C 75 95<br />
KILN MOTOR 301 NDE<br />
BRG TEMP<br />
KILN GEAR BOX<br />
TEMPERATURE - 1<br />
KILN GEAR BOX<br />
TEMPERATURE - 2<br />
KILN GEAR BOX<br />
TEMPERATURE - 3<br />
KILN GEAR BOX<br />
TEMPERATURE - 4<br />
0C 85 95<br />
0C 75 90<br />
0C 75 90<br />
0C 75 90<br />
0C 75 90<br />
Time of<br />
best<br />
achieved<br />
13-Jan-10<br />
11:42:39<br />
14-Jan-10<br />
11:39:56<br />
14-Jan-10<br />
11:39:56<br />
14-Jan-10<br />
11:39:56<br />
08-Mar-10<br />
07:31:48<br />
14-Jan-10<br />
03:09:28<br />
10-Jan-10<br />
05:24:30<br />
07-Aug-10<br />
16:19:43<br />
14-Jan-10<br />
11:39:56<br />
14-Jan-10<br />
11:39:56<br />
Best<br />
achieved<br />
41.5<br />
31.7<br />
33.3<br />
34.9<br />
40.5<br />
40.2<br />
52.2<br />
47.6<br />
58.5<br />
58.7<br />
1 2 3<br />
45.6<br />
43.1<br />
43.2<br />
48.7<br />
49.3<br />
62.1<br />
60.1<br />
45.3<br />
62.0<br />
64.6<br />
47.1 45.9<br />
44.1 41.6<br />
45.8 42.8<br />
48.4 47.9<br />
49.4 48.1<br />
62.3 59.2<br />
57.8 55.4<br />
44.0 42.5<br />
61.9 59.8<br />
64.9 63.6<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC
CONCLUSIONS<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC
FUTURE PLAN<br />
RC IV at Karnataka<br />
GCR 2 at Raipur<br />
KARUR at TN<br />
Provision of PI-ERP<br />
Connectivity<br />
Migration to PI 2010<br />
Platform<br />
NEW PROJECTS<br />
TO HAVE INTEGRATED<br />
INFO SYSTEMS FROM<br />
DAY 1<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC
© Copyright 2011 <strong>OSIsoft</strong>, LLC
23 September 2011<br />
WESTIN GARDEN CITY,<br />
MUMBAI<br />
Applying PI System – For <strong>Improving</strong> Process<br />
Condition & Process Optimization<br />
Presented by: Lalit Pokharana - Senior Engineer (Instrumentation)<br />
UltraTech Cement Limited<br />
Unit: Kotputli Cement Works ,Raj<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 32
Agenda<br />
<strong>OSIsoft</strong> products <strong>and</strong> services.<br />
Overview of Kotputli Cement Works.<br />
PI System Architecture at Kotputli Cement Works.<br />
PI Utilization as Kotputli Cement Works.<br />
Business Challenges & solutions.<br />
Examples - Process Optimization.<br />
Case Study – Process Optimization.<br />
Results & benefits.<br />
Future Plans.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 33
Overview of Kotputli Cement Works<br />
MTPD Year Status<br />
10,000 2009 Greenfield plant.<br />
PI SYSTEM<br />
INSTALLED IN THE<br />
2011 JAN.<br />
We are committed to Green, Clean <strong>and</strong> Safe environment.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 34
PI SYSTEM ARCHITECTURE<br />
A B<br />
E<strong>the</strong>rnet LAN<br />
FIREWALL<br />
SWITCH<br />
Redundant DCS Servers<br />
(5000 Tags)<br />
PI Server<br />
Client 1 Client 2 Client 3 Client 4……… ...Client n<br />
QCX<br />
XRF XRD CBA<br />
Aditya Birla Group<br />
O<strong>the</strong>r Units Remote<br />
PI Server & Client<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 35
PI Utilization At KOTPUTLI<br />
Functionalities to cover:<br />
•Data extraction (interface)<br />
•Plant configuration <strong>and</strong> templates manager<br />
•Reports generation<br />
•Interfaces to ano<strong>the</strong>r systems (e.g. QCX,XRF,XRD,FUZZY SYSTEM)<br />
•Process scope includes:<br />
Raw mill<br />
Kiln<br />
Coal mill<br />
Cement mill<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 36
PI Utilization At KOTPUTLI<br />
How we use <strong>the</strong> PI System at our plant<br />
• PI Clients installed in all maintenance departments –<br />
Quality, Production, Mechanical, Electrical, Instrumentation & MID.<br />
• Real time data monitored at Quality Control <strong>and</strong> Mines department.<br />
• Monitoring of o<strong>the</strong>r cement units process parameters.<br />
• SMS notification for real time monitoring of plant running status <strong>and</strong> <strong>the</strong><br />
PGNAA Data to Mines Department in mines area through SMS :-<br />
SiO2=30.66 ,CaO=29.83, MgO=30.34 K2O =15.20,LSF=29.13,Na2O=29.67<br />
Quality has been one of our priorities<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 37
Business Challenges<br />
•Correlate quality <strong>and</strong> operations data .<br />
•Time to consolidate quality data from lab equipment to mines & process.<br />
•Incorporate quality data to a real-time platform .<br />
•St<strong>and</strong>ardize <strong>and</strong> simplify access to data .<br />
•Reduction of Total Cost.<br />
•Reducing Fossil Fuel & Electric Power costs involves efforts from different<br />
process areas, with <strong>the</strong> majority falling on <strong>the</strong> Cement Making Operations.<br />
•In addition, a better mix of alternative <strong>and</strong> fossil fuels could reduce <strong>the</strong><br />
environmental footprint even more.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 38
Business solution<br />
Mining<br />
SIO2 CAO MGO<br />
Mines engineers take<br />
corrective action without<br />
information from QC.<br />
03/11/2009<br />
Crushing<br />
CBA<br />
PI Notification<br />
(SMS ALART)<br />
Stacking &<br />
Reclaiming<br />
Raw Meal<br />
Milling<br />
SiO2=30.66 ,CaO=29.83, MgO=30.34<br />
K2O =15.20,LSF=29.13,Na2O=29.67<br />
QCX<br />
CBA<br />
XRF<br />
Q XRD<br />
Q<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
39
Results<br />
• Single Platform for Quality <strong>and</strong> Production data .<br />
•St<strong>and</strong>ardization .<br />
•Real-time Quality KPI’s .<br />
•Faster data ga<strong>the</strong>ring process .<br />
•Enhanced data security .<br />
•Easy corporate consolidation .<br />
•Cross business visibility in internal units of grasim.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
40
Process Optimization Case Study<br />
• Communication<br />
with Central<br />
Control room<br />
minimized.<br />
• PI DataLink Helps<br />
in breakdown<br />
analysis.<br />
• PI ProcessBook<br />
help in real time<br />
data monitoring.<br />
• Effective<br />
equipment health<br />
monitoring.<br />
• Huge Databank for<br />
analyzing plant<br />
behavior in<br />
different process<br />
conditions.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 41
Process Optimization Report<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC 42
Intangible benefits<br />
• Real-time quality measurement results ensure high-quality cement/clinker<br />
production.<br />
• Production <strong>and</strong> quality data correlation .<br />
• Automatically generated notifications at mail & phone(SMS).<br />
• Validated production information; verified data quality; monitoring <strong>and</strong> reporting of<br />
exactly where losses occur; calculation of monthly reconciled recovery .<br />
• Reduction in total energy consumption.<br />
• Integrate X-ray(QCX,XRF,XRD) equipment from different vendors .<br />
• Eliminate risk of technology obsolescence.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
43
Future plans <strong>and</strong> next steps<br />
• Connectivity of PI Server over OPC for :<br />
QCX SYSTEM.<br />
Thermal Power Plant.<br />
Energy Management System.<br />
• Linking PI data to SAP.<br />
• Underst<strong>and</strong>ing <strong>and</strong> Implementation of latest <strong>OSIsoft</strong> products.<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
44
Questions<br />
© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />
45
© Copyright 2011 <strong>OSIsoft</strong>, LLC